APPARATUS AND METHOD OF SAW FOR ROLLED PRODUCT LOGS FIELD OF THE INVENTION The present invention relates to saw assemblies for winding products and more particularly to saw assemblies having mandrels for at least partially supporting the wound products while they are cut by a saw for logs of winding or rolled products. BACKGROUND OF THE INVENTION
[0002] Rolled products, such as toilet paper, paper towels, waxed paper, thin metal foil, plastic sheets, cloth or other materials that are in sheet form, typically are produced in two ways. Rolled products are made either with a core at the center of the roll or without a core at the center of the roll. Due to the cost and manufacturing constraints associated with the use of a core, it has become advantageous to produce coiled products without a core. However, to allow a coreless product to be used with the existing jets designed for coiled core products, it is typically necessary to include a longitudinal opening through the coiled coreless product. Coreless rolled products are typically made in winding mandrels to create the central opening that extends over the longitudinal axis of the rolled product. The winding mandrel forms a relatively long trunk of the rolled product which is then cut into usable stretches or rolls by a log saw. A disadvantage of rolled products without a core is that the central opening has the tendency to collapse when the log is cut into rolls by the log saws. Even in rolled products having a core, the amount of force exerted on the rolled product during some cutting operations can cause the core to deform or crush if it is not at least partially supported by a mandrel. For example, some rolled products may be easily deformable or may require larger cutting forces capable of bending, deforming, crushing or otherwise damaging the rolled product if not held by a mandrel. Additional design limitations arise due to the conventional practice of cutting logs with a saw that must stop through a section equal to the trunk diameter in order to complete its cut. A razor or blade that must pass deep into the log, can often generate significant friction, heat and undesirable forces during cutting operations and can result in poor cuts and poor product quality. Different methods have been developed to alleviate this problem in rolled products with or without core. For example, tightening the winding of the rolled product without a core can increase the stiffness and firmness of the rolled product, thereby reducing the amount of crushing of the opening. Although this solution can reduce crushing, it can also increase the friction between the saw blade and the trunk, thus increasing the difficulty of cutting the log into rolls and requiring higher cutting forces. In combination with or as an alternative to tighten the winding of a rolled product, some saw mounts include a mandrel that is received within the trunk opening to maintain the shape of the opening during the cutting process and reduce the amount of crushing of opening. Some saw assemblies such as that described in US Pat. No. 5,271, 137, include a mandrel fully located on one side of the saw blade during cutting operations on the trunk. The mandrel includes an end that is located adjacent a saw disc to support the opening when the saw or cutter disc moves through the trunk to cut a log roll. Other saw mounts such as that described in U.S. Pat. No. 5, 453,070, include a first mandrel located on one side of the saw disk and a second mandrel located on the set side of the saw disk. Each mandrel includes an end disposed adjacent the saw disc to support the opening when the saw disc moves through the trunk between the ends of the mandrels. Although it is the intent of these saw mounts to support the opening near the saw blade during cutting, these saw mounts still allow a substantial amount of crush opening, which can result in a poor quality cut. In addition, the use of two mandrels (and associated elements and equipment) adds a significant cost to the machine that cuts logs of coiled material. In light of the above design requirements and limitations, there is a need for a saw assembly that includes a mandrel, which provides superior support of the central opening of a log during the cutting process, reduces crushing of the opening during the process cutting and allows rotation of the trunks during the cutting process in such a way that the saw blade cuts a log roll after passing through less than a diameter of the rotating log, thereby reducing the force and friction applied to the trunk by the cutting disc. Each of the preferred embodiments of the present invention achieves one or more of these results.
SUMMARY OF THE INVENTION In some preferred embodiments of the present invention, an apparatus and method are employed for cutting a rotating log into rolls used to prevent or reduce the crushing of an opening extending longitudinally in the trunk during the cutting process. Some embodiments of the present invention preferably include a mandrel received within the trunk opening for at least partially supporting the trunk and maintaining the integrity of the opening while the trunk is cut by a saw blade. The mandrel may include a longitudinal axis, a first portion, and a second portion on the longitudinal axis. The first portion preferably includes a radially outermost surface defining a first radial distance from the longitudinal axis, a second portion that preferably includes a radially outermost surface defining a second radial distance from the longitudinal axis, which may be the same or different from the first radial distance. Preferably, the saw disk is movable towards the longitudinal axis to a cutting position between the first portion and the second portion. In the cutting position, the mandrel preferably has a third distance between the saw disk and the longitudinal axis, the third distance is shorter than at least one of the first and second radial distances, in order to locate the saw by under the surfaces of the first and second portions. By locating the saw disc below the surfaces of the first and second portions and rotating the trunk, the saw disc is able to cut a log roll after partially moving through the trunk. Preferably, the outer surfaces of at least one of the first and second portions maintains the shape of the opening adjacent the saw disc during the cutting process. More preferably, the outer surfaces of both the first and second portions maintain the shape of the opening adjacent the saw disk during the cutting process. In some preferred embodiments of the invention, the mandrel is rotatable with the trunk and includes a third portion connecting the first and second portions. Preferably, the third portion includes a radially outermost surface defining the third radial distance of the longitudinal axis. The saw disc is or can preferably be aligned with the third portion and is movable to the cutting position, such that the saw disk is located below the surfaces of the first and second portions and avoids contact with the blade. third portion as the mandrel rotates with the trunk. The third portion preferably is a recess extending around a circumference of the mandrel. In some embodiments, the recess transits non-abruptly in the first and second portions, such as by having side walls that are joined with the surfaces of the first and second portions at a non-orthogonal angle, by a radiated transition surface between the side walls and the surfaces of the first and second portions and the like. The transition may preferably reform any partial crushing of the opening as long as the log and the roll move axially to relocate the log for the next cut or remove the log or log from the mandrel. Although a mandrel having a recess extending with respect to the circumference of the mandrel can be rotatable with the trunk as just described, the mandrel can instead be held against rotation in cases of logs that can be rotated with respect to the mandrel during operations of cut. In other preferred embodiments of the invention, the mandrel is clamped against rotation, includes a third portion that connects the first and second portions and defines a recess that opens toward the saw disk and can only extend partially around a mandrel circumference. The recess may be deeper or shallower than the radius of either or both the first and the second portions (ie deeper or less deep than the length of the first or second radial distances). The saw disc is or may preferably be aligned with the third portion and movable to the cutting position, such that the saw disk is located below the surface of the first and second portions and does not contact the third portion of the non-rotating mandrel. As with mandrels having a recess that extends completely around the mandrel as described above, the third portion preferably travels non-abruptly in the first and second portions. In addition, the preference recess transits non-abruptly on a more external surface of the third portion joining the first and second portions. The transition may preferably reform any partial crushing of the break as long as the log and the roll rotate around the third portion of the mandrel. More preferably, the third portion is held against rotation in this embodiment, while the first portion is rotatable with the trunk relative to the third portion. For example, the third portion may be located on an arrow, while the first portion may be a sleeve rotatably coupled to the arrow. More preferably, the second portion may also be rotatable and may be an additional sleeve rotatably coupled to the arrow on one side of the third portion opposite the first sleeve. In other preferred embodiments of the invention, the mandrel includes two or more recesses, each having a depth at a corresponding radial distance from the longitudinal axis. Preferably, the mandrel is axially movable to align the saw with the different recesses. Alternatively or in addition, the saw (or blade) can be mobile to align the different recesses with the saw. The saw disk is preferably movable towards the longitudinal axis to a cutting position within any of the recesses. Each cutting position defines a radial position that is preferably shorter than at least one of the first and second radial distances. Preferably, by locating the saw disc below the surface of the first and / or second portions in one of the aligned positions and rotating the trunk, the saw disk is able to cut a log roll after partially moving. through the trunk. Also, preferably by axially moving the mandrel to align the saw disc to another position, further cuts in the trunk can be made in a similar manner. Other features and advantages of the invention will be apparent to those skilled in the art, upon review of the following detailed description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a side elevational view of the saw assembly according to a preferred embodiment of the present invention; Figure 2 is an enlarged side view of a mandrel according to a preferred embodiment of the present invention; Figure 3 is an enlarged side view of a mandrel according to another preferred embodiment of the present invention; Figure 4 is an end elevational view of the saw assembly illustrated in Figure 1;
Figures 5-1 1 are side elevational views of the saw assembly shown in Figure 1, illustrating the advance of a saw blade or cutter and a mandrel of the saw assembly illustrated in Figure 1. Before it is explain in detail one embodiment of the invention, it will be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other modalities and of being practiced or carried out in various forms. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and shall not be considered as limiting. The use of "including" and "comprising" in their variations here is intended to cover the items listed below and their equivalents as well as additional items. The use of "consists of" and its variations here is understood to cover only the items cited later. The use of letters to identify elements of a method or process is simply for identification and is not intended to indicate that the elements should be made in a particular order. DETAILED DESCRIPTION Figure 1 illustrates a saw assembly 10 incorporating features of the present invention for cutting a log 12 of a rolled product, in rolls (14) for example rolls of size for consumer use). The trunk 2 includes a centrally located, longitudinally extending opening 16. The saw assembly 10 may include any assembly or mechanism for transporting logs of wound material to the circular blade 38. These assemblies or mechanisms may include one or more conveyors, carriages , ramps and similar. In the preferred embodiment illustrated, for example, the saw assembly 10 includes a log bucket 18 that feeds the log 12 to a log indexing conveyor 20 that leads to the circular blade 38. The log indexing conveyor may take any desired shape, such as one or more of band, chain, table or other types of conveyors. In the preferred embodiment illustrated in Figure 1, the log indexing conveyor 20 includes a log channel 22, which supports the log 12, although in any other form and arrangement of conveyor 20 it may be used in its place, as desired . The conveyor 20 preferably includes an impeller 24 which moves to push the trunk 12 towards the circular blade 38. The impeller 24 can operate only to push the trunk 20 towards the circular blade 38 or it can work in conjunction with one or more bands, chains or other transportation elements of the conveyor 20, to perform this function. The impeller 24 (if employed) may have a plate, plug, bar or other mobile element for contacting and pushing the trunk 12 as just described, or it may be mobile in any conventional manner such as by connection to a carriage on a rail or track to a rack and pinion assembly, to a hydraulic or pneumatic cylinder and the like. The saw assembly 10 also preferably includes a rotary clamp assembly 28 which receives the trunk 12 of the impeller 24 (or other log conveyor) and holds and rotates the trunk 12 relative to a longitudinal axis 30 of the trunk 12. The assembly of Illustrated clamp 28 includes two rotating clamps 32 located in an end-to-end relationship and defining a space 34 between the clamps 32. Alternatively, the trunk can be rotated by a single clamp 32 located on one side of the saw disk of the trunk 40. In those embodiments having two clamps 32, the clamps 32 are preferably rotated in tandem by a motor 36 and selectively adjusted to vary the clamping pressure against the trunk 12. An example of this rotatable clamp assembly 28 is illustrated and described in the US patent No. 5,755,146 which is commonly owned by the assignee of this application. In alternate form, each clamp can be displaced by a respective motor as desired, and can provide pressure adjustments without clamp or limited. Although the use of a rotating clamp assembly 28 is preferred, another embodiment employs a clamp assembly that does not rotate, or instead may not employ de facto clamp assembly (in which case the product wound on the mandrel may be rotated by rotation of the mandrel, by one or more rollers in contact with the rolled product or any other desired shape). The saw assembly 10 includes a saw 38 which includes a saw disc 40 defining a plane 42 preferably aligned with the space 34 between the clamps 32 and which is preferably coupled to an orbital head 44 for rotation with respect to an axis of Saw disc 46. Preferably, orbital head 44 engages a saw base 48 for rotation relative to a head shaft 50. Saw disc 40 and orbital head 44 are preferably independently displaced for rotation by motors ( not shown) indicated within the base of saw 40 or otherwise connected in a driven manner to the orbital head. Preferably, the saw blade shaft 46 is moved by the orbital head 44, such that the saw disk 40 moves on an arcuate path. By rotating the orbital head 44, the saw disc 40 moves from a position radially outside the clamps 32 to a position within the space 34 between the clamps 32. Furthermore, the arcuate movement of the saw disk 40 allows the disk saw 40 cut multiple logs 12 located side by side in different tracks as illustrated by way of example in Figure 4. Although any number of tracks can be used with the present invention to increase productivity, the preferred embodiment illustrated in Figures 1 and 5-11 will be described as a single track device. Also, in other embodiments of the present invention, different types of saw and cutting devices can be used as alternatives to the orbital saw of the preferred embodiment illustrated. These alternating saws and cutting devices include, without limitation, band saws, wire saws, non-orbital rotating blades, reciprocating blades and the like, all of which are understood to fall within the terms "saw" and "blade" as referred to herein. and in the appended claims. The saw assembly 10 also includes a mandrel 52 which preferably has a first cantilevered end mounted to a mandrel support bracket 54. The mandrel support bracket 54 is preferably coupled to a mandrel conveyor 56 for moving the mandrel. 52 in a longitudinal direction. Alternatively, the mandrel 52 can be moved longitudinally by any other device known to those skilled in the art to provide linear or substantially linear movement such as a hydraulic or pneumatic cylinder, a threaded or helical impeller, a motor that drives the mandrel. 52 by any conventional power transmission elements or devices, a rack and pinion assembly, a carriage mounted on a rail or track on which the mandrel 52 is connected or another such device, Preferably, the conveyor 56 moves the mandrel 52 towards and away from the clamp assembly 28. More preferably, the mandrel 52 moves between a position where a recess 58 in the mandrel 52 is located within the clamp assembly 28 and another position where the entire mandrel 52 is out of assembly of rotary clamp 28 and partially or completely beyond a fixed detachment element 60. The detachment element 60 can be a plate, a bar, a rod or other element or structure adjacent to the mandrel 52 to detach the product (eg rolls of the trunk 12) from the mandrel 52, as the mandrel 52 moves relative to it. In a preferred embodiment illustrated for example, the detachment element is a plate 60. In other embodiments, the detachment plate or other detachment element 60 may be movable to perform the mandrel release process, such as by connecting any of the elements or structures described above with reference to the longitudinal movement of the mandrel 52. As mentioned above, the mandrel 52 preferably has a recess 58. This recess 58 is preferably located in a position between the ends of the mandrel 52. As used herein, and in the appended claims, the term "recess" is not limited to any particular configuration, notch, cut, recess or cavity within the mandrel 52. Specifically, the recess 58 can be produced in any form (for example machining, molding, forming, casting and the like) which can take any shape that allows the saw disk 40 to move beyond the outermost surfaces of the mandrel portions 52 which and flank the recess 58, such that the saw disk 40 can move in the recess 28 to a position that is radially closer to a longitudinal axis 62 of the mandrel 52 than the outermost surfaces of the issues of the mandrel 52 are raised in the recess 58. It will also be noted that the saw disc 40 in this position is also referred to throughout the present description and claims as being "underneath" one or more surfaces of the mandrel 52, although the term "by "below" only refers to the ratio of the saw disc 40 to the mandrel surfaces or and does not indicate or imply any orientation of the mandrel 52, saw 38 or other part of the saw assembly 10 with respect to the surrounding environment. Although some preferred embodiments (such as the preferred embodiment illustrated) employ a mandrel 52 having a round cross-sectional shape, the mandrel 52 can instead be of any shape and configuration that allows the mandrel 52 to be located within the opening 16 of the trunk 12 or roll 14, to assist in maintaining the integrity of the opening 16. For example, the cross section of the mandrel 52 may be triangular in shape, rectangular in shape, star-shaped, or may have any other shape that provides a contact surface which at least partially supports the trunk 12 or roll 14, when the mandrel 52 is located within the opening 16. Further, as employed throughout the specification and the claims, a "radio" or "radial distance" it is used to identify the distance from the longitudinal axis 62 of the mandrel 52 to any other point in the same or substantially the same longitudinal position on the mandrel 52 , whether the cross-sectional shape of the mandrel 52 is round or not. For example, if the mandrel 52 includes a triangular cross-sectional shape, then the distance between the longitudinal axis 62 and a point defined by one of the cusps of the triangle, can be referred to as a radius or a radial distance. Similarly, the distance between the longitudinal axis 62 and a triangle point between the two cusps of the triangle is also referred to as a radius or radial distance. Although in the preferred embodiment illustrated, the outer periphery of the mandrel 52 preferably has a constant or substantially constant cross-sectional shape between the ends of the mandrel 52, it should be noted that a non-constant cross-sectional shape is also within the range of the present invention. For example, the mandrel 52 may taper in one or more directions at any point on the length of the mandrel 52, may taper or drift intermittently, may have a stepped outer surface on any portion of the mandrel 52, may have an outer periphery that expands and it contracts over the length of the mandrel 52 or can have any other desired non-constant longitudinal shape. In some embodiments of the present invention, the saw assembly 10 also includes one or more conveyors located or to position, to transport the product (eg, cut product rolls, uncut portions of the trunk 12 and the like) away from the saw 38. This conveyor or conveyors can be of any type, including those described above with reference to the trunk indexing conveyor 20. Also, in some embodiments, one or more of these conveyors can be moved to and from a position to receive the product from the mandrel 52. By way of example only, the preferred embodiment shown in Figure 1 has a moving conveyor 64 and a product discharge conveyor 66 located side by side with each other. The mobile conveyor 64 preferably includes a rotating band 68 which is coupled to actuators 70 which move the band 68 towards and away from the mandrel 52. Any other conventional system or device may be employed in place to move the rotating band 68 toward and away of the mandrel 52. The product discharge conveyor 66 preferably includes a rotating band 72 positioned to receive the product from the moving conveyor 64 and transport the product out of the saw assembly 10.
Figure 2 illustrates the mandrel 52 according to a preferred embodiment of the invention. The mandrel 52 includes a central arrow 64 which is preferably mounted at one end to the clamp through the mandrel support 54 which is clamped against rotation. The central arrow may be solid or hollow, and preferably includes a tapered tip 66 at the distal end and a non-rotating portion 78 between the ends of the mandrel 52 including the recess 58. The tapered tip 76 may assist in the proper attachment of the mandrel 52 with a trunk 12 as described above, although other tip shapes may also be employed to perform this function, such as rounded tip shapes. In still other embodiments, the end of the mandrel has no tapered or rounded tip. In order to allow the product in the mandrel 52 to rotate relative to the mandrel 52 during cutting operations on the trunk 12, bearings 80 are preferably coupled to the central arrow 74 on one side of the non-rotating portion 78, to rotatably support a main sleeve 82 on the central arrow 74. Preferably, other bearings 84 also engage the central arrow 74 on the other side of the non-rotating portion 78 opposite the main sleeve 82 to further rotationally hold 86 on the arrow 74 between the bearings 84. Bearings 80, 84 may be of any conventional shape, such as impulse bearings, ball bearings, roller bearings, journal bearings or plain bearings and the like. Although the bearings 80, 84 and sleeves 82, 86 are preferably used on both sides of a recess 58, in some embodiments a bearing 80, 84 and / or sleeve are located on only one side of the recess 58. In other embodiments (such as like those where the trunk 12 and the mandrel 51 have a spacing fit) no bearings are used on the mandrel 52. Instead, the trunk 12 contacts and rotates relative to the stationary arrow 74 or is received on the sleeves 82, 86 having a sufficiently clear fit to rotate against the stationary arrow 74. Again with reference to the embodiment of the mandrel 52 illustrated in Figure 2, the spokes of the radially outermost surfaces of the sleeves 82, 86 and the spokes of the radially outermost portion of the non-rotating portion 78 are preferably substantially equal, although differences in radii are possible in some embodiments. With reference to Figure 1, the saw assembly 10 preferably includes a motor 88 that rotates the main sleeve 82 relative to the central arrow 74 to rotate with the trunk 12 during the cutting process. As illustrated in Figure 2, the recess 58 extends only partially around the mandrel 52 leaving one side of the non-rotating portion 78 without undercutting. Preferably, the recess 58 of the non-rotating portion 78 transitions circumferentially in a non-abrupt manner in the non-recessed portion of the non-rotating portion 78. Also, the recess 58 preferably transits non-abruptly in the portions of the non-abrupt portion. rotary 78, flanking the recess 58 about the longitudinal axis. The non-abrupt transitions of the non-rotating portion can be defined in a number of different ways, such as recessed surfaces are at an acute angle with respect to the recess 58, as illustrated in Figure 2, can be defined by curved walls or arched of the recess 58 and the like. The present invention is not limited to the preferred mandrel 52 described above and illustrated in Figure 2. For example, and as described in more detail above, the mandrel 52 can be fully clamped against rotation such that the recess 58 always faces the the saw disc 40 and the trunk 12 and the cut rolls 14 slidably contact the mandrel during rotation and translation of the trunk 12 and the rolls 14 relative to the mandrel 52. In other embodiments, the whole mandrel rotates as the mode illustrated in the Figure 3. With reference to Figure 3, the mandrel 152 includes an arrow 174 which is mounted on one end of the mandrel support bracket 54. The mandrel 152 includes a tapered tip 166 at the distal end of the mandrel 152 to assist in locating the mandrel 152 within the aperture 16. of the trunk 12, although other shapes of mandrel end may be employed as described in more detail above. The mandrel 152 includes a recess 158 that extends completely around the mandrel 152. Preferably, the recesses 158 transit non-abruptly to the first and second portions Pi, P2, of the mandrel flanking the recess 158, which defines a third portion. P3. It is also illustrated in Figure 3, that the first portion? ,, includes a radially outermost surface defining a first radial distance Di of the longitudinal axis 62, the second portion P2 includes a radially outermost surface defining a second radial distance Di of the longitudinal axis 62, the saw disc 40 (illustrated in the cutting position) defines a third radial distance D3 between the saw disc 40 and the longitudinal axis 62 and the third portion P-, includes a radially innermost surface that defines a fourth radial distance D from the longitudinal axis 62. The operation of a preferred embodiment of the saw assembly according to the present invention is described with reference to Figures 5-1 1. As illustrated in Figure 5, the trunk 12 it is illustrated in the trunk bucket 18 ready to be loaded on the trunk indexing conveyor 20. With reference to Figure 6, the trunk bucket 18 drops from the trunk 12 in the The trunk indexing conveyor 20, the impeller 24 moves the trunk 12 towards the clamp assembly 28. Preferably, the mandrel 52 moves simultaneously towards the clamp assembly 28. The orbital head 44 keeps the saw disk 40 away from the rotary clamp assembly 28. As illustrated in Figure 7, the mandrel 52 enters the rotary clamp assembly 28 and aligns the recess 58 with the plane 42 of the saw disk 40 and the space 34 between the rotary clamps 32. Preferably , the impeller 24 moves the trunk 12 within the rotary clamp assembly 28, placing the mandrel 52 into the opening 16 of the trunk 12. The motor 36 rotates the clamps 32 and the motor 88 to rotate the main sleeve 82 with the trunk 12 The orbital head 44 moves the saw disc 40 through the space 34 between the clamps 32 and within the recess 58 of the mandrel 52 to cut a roll 14 from the rotating log 12. With further reference to Figure 2, The saw disc 40 preferably remains in the recess 58 as the log 12 is rotated to ensure that the log 14 is completely cut off from the log 12. The mandrel portions 52 that flank the recess 58 maintain the integrity of the opening 16 during the cutting operation. The small amount of paper that can deviate within the recess 58 due to the pressure generated by the circular disk 40, can be reformed to its original position as the trunk 12 and the roll 14 rotate around the bottom of the non-rotating portion 68 of the mandrel 52 , where the recess 58 is not present. By virtue of the configuration of the recess 58, the flanking portions of the mandrel 52 reduce deflection of the opening 16 by supporting the opening 16 on both sides of the saw disc 40 and then reforming the opening 16 according to the trunk 12 and the roll 14 rotate about the non-rotating portion 68 of the mandrel 52. The use of a non-abrupt transition between the recess 58 and the mandrel position 52 on the opposite side of the mandrel 52, is effective to gently reshape the paper biased outwardly to the shape of the opening 16 as the trunk 12 and the roll 14 rotate about the non-rotating portion 78. As an alternative, other types of transitions between the recess 58 and the opposite non-recessed side of the non-rotating portion, may be employed to achieve the same results. As well, the transition (preferably not abrupt) between the recess 58 and the portion of the mandrel 52 flanking the recess 58, can smoothly reform the paper deviated outwardly to the shape of the opening 16, when the trunk 12 and the roll 14 advance through the impeller 24 further to the mandrel 52. In other embodiments of the present invention such as that illustrated in Figure 3, the mandrel 152 (more specifically the mandrel portions 152 adjacent the recess 58) do not reform the aperture 16 during rotation of the mandrel 152. Instead, the mandrel 152 reforms the opening 16 when the driver 24 moves the trunk 12 and the roll further away on the mandrel 152. Specifically, the non-abrupt transition 160 between the radially innermost surface of the third portion P3 and the outer surface of the first portion reform the paper deviated outwardly to the shape of the opening 16, when the trunk 12 and the roll 14 are advanced by the impeller 24 plus ale upwardly of the mandrel 152. After the roll 14 is cut, the orbital head 44 preferably moves the saw disk 40 away from the rotary clamp assembly 28, so that the driver 24 can move the trunk 12 and the roll 14 towards the mandrel 52, a distance equal to the length of the next roll 14 to be cut, which typically remains consistent for the entire trunk 12. Eventually, the cut roll 14 is pushed out of the rotary clamp assembly 28 and slides further apart on the mandrel 52. In the preferred embodiment illustrated, the mandrel 52 is held against axial movement to maintain the recess 58 in alignment with the plane 42 of the saw disk 40. With reference to Figure 8, the saw assembly 10 is cut off most of the trunk 12 in products to size for the consumer. Each cut roll 14 is pushed by the impeller 24 to slide further up the mandrel 52, forming a row 90 of cut rolls 14. After the last roll 14 is cut from the log 12 as illustrated in Figure 9, the orbital head 44 preferably moves the saw disk 40 away from the rotary clamp assembly 28. Preferably, the impeller 24 moves the uncut portion of the stem 12 through the rotary clamp assembly 28 and onto the mandrel 52. In the Figure 10, the actuators 70 of the moving conveyor 64 raise the band 68 towards the mandrel 52 to a position adjacent to the cut rolls 1 in the mandrel 52. Preferably, the mandrel conveyor 56, moves the mandrel 52 away from the rotary clamp assembly 28, to cause the first cut roll 14 to contact the release plate 60. The release plate 60 pushes the rolls 14 out of the mandrel 52 and on the band 68 as the mandrel conveyor 56 continues ua by moving the mandrel 52 away from the rotary clamp assembly 28. As illustrated in Figure 11, the mandrel 52 moves to completely remove the rolls 14 from the mandrel 52 and the impeller 24 returns to the starting position away from the clamp assembly rotary 28. The cycle is completed when the actuators 70 lower the web 68 supporting the cut rolls 14 to align the web 68 with the web 72 of the product discharge conveyor 66, such that the rotation of the webs 68, 72 moves the webs. cut rolls 14 to downstream operations (such as a packaging machine or equipment).
In another method of using the log saw assembly 10 according to the present invention, a mandrel (such as a winding mandrel (not shown)) similar to the mandrel 52 described above, moves away within the log 12 and is loaded into the trunk indexing conveyor 20. In this case, the trunk 12 and the winding mandrel can be clamped at the end opposite to the rotary clamp assembly 28 such that a recess 58 of the winding mandrel can be aligned with the plane 42 of the saw disc 40. Preferably, the driver 24 will then index the log 12 in the rotary clamp assembly 28 while the winding mandrel remains stationary, to thereby index the cut rolls 14 separated from the winding mandrel and on a conveyor similar to the mobile conveyor 64 or the conveyor for unloading the product 66. In a further embodiment of the invention, the mandrel 52 includes multiple recesses 58 and is mobile to to selectively align each of the multiple recesses 58 with the plane 42 of the saw disk 40. The mandrel 52 can be used in a manner similar to that described above, except that the mandrel 52 will be located within the trunk 12 and will preferably index with the trunk 12 for aligning sequential recesses 58 with the saw disc 40 to cut the next roll 14 of the trunk 12. Alternatively, the mandrel 52 can be used with a saw 38 that includes multiple saw discs 40 and additional clamp assemblies 28 The saw blades 40 are preferably coupled together and are offset from one another on the axis of the saw blade 46, and the additional clamp assemblies 28 (rotating or non-rotating) are preferably located in an end-to-end relationship. -extreme with the other clamp mounts 28. Each saw disk 40 will move between a space 34 between adjacent clamps 32 and within a respective recess 58. In this way , the driver 24 can index the trunk 12 to larger increments because each step of the saw discs 40 will make more cuts through the trunk 12. Accordingly, a mandrel 52 having one or more recesses 58 in accordance with the present invention can be stationary to receive the rolled-up product therein pushed, it can be movable to be inserted within the rolled product moving simultaneously with respect to the mandrel 52 or it can be movable to be inserted into the stationary or substantially stationary rolled product. In the case where both the mandrel 52 and the rolled product are movable, the mandrel and the rolled product can be moved in stages, simultaneously or in any other desired form. In any case, the rolled product preferably is cut as described above as it is placed on the mandrel 52 upon removal from the mandrel 52 or between these operations. The modalities described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. As such, it will be appreciated by a person of ordinary skill in the art that various changes in the elements and their configuration and arrangements are possible without departing from the spirit and scope of the present invention as set forth in the appended claims.